Method for forming designs in knitted or woven fabrics of synthetic polyamide fibers



May 1, 1951 F. G. WEISBECKER 2,550,894

METHOD FoF FoRMING DESIGNS IN KNITTED 0E wovEN FABRICS oF SYNTHETIC FOLYAMIDE FIBEEs May l, l951 F. G. wElsBEcKER 2,550,894

METHOD FOR FORMING DESIGNS IN KNITTED OR WOVEN l, FABRICS OF SYNTHETIC POLYAMIDE FIBERS Original Filed Nov. 29, 1947 3 Sheets-Sheet 2 FHM/4 G, Weis/Jeder Htor/z ery.

May 1, 1951 F. G. WEISBECKER 2,550,894

METHOD FOR FORMING DESIGNS IN KNITTED OR WOVEN 0F SYN R THETIC POLYAMIDE FIBERS Original Filed Nov. l I5 Sheets-Sheet 5 Jig. Hztorncy.

Patented May 1, 1951 METHOD FOR FORMING DESIGNS IN KNETTED R WOVEN FABRICS 0F SYNTHETICA POLYAMIDE FIBERS Frank G. Weishecker, Glenside, Pa., assigner to Perforations, Inc., Palmyra, N. J., a corporation of New Jersey rOriginal application November 29, 1947, Serial 788,852. Divided and this application March 17, 1950, Serial No. 160,281

(c1. ifi- 56) 2 Claims. 1

'Ihis invention pertains to the formation of designs infabrics knitted or woven from synthetic polyamide bers, commonly known as nylon. The primary eld of use of the invention is in the formation of designs in nylon stockings, .but it will be seen that in practice designs may be applied to other nylon fabrics as well.

Designs, such as trade-mark insignia, size or grade numerals or letters, etc., have been ap plied to the welt of nylon stockings in numerous ways. Such methods have been confined, however, to conventional printing processes which require liquid printing inks, or similar fluids, and which result in a design that is not completely permanent.

Therefore, an object of this invention is to devise a method of applying a permanent design to a fabric knitted or woven from synthetic polyamide bers without damage thereto.

Another object of the invention is to devise a novel method of applying a design to nylon fabrics without the use of printing liquids.

Other objects and uses of the invention will be evident from the following description and accompanying drawings in which:

Figure l is an elevational view of one form in Figure l with parts broken away to show the heating coil details.

Figure 4 is a plan view of the pattern member shown in Figure 1.

Figure 5 is a perspective View of a portion of the apparatus shown in Figure 1 provided with another type of heating means.

Figure 6 is a plan view of a portion of a fabric with a typical design formed therein in accordance with this invention.

Figure 7 is an elevational view of a preboarding form incorporating another form of apparatus for forming a design in accordance with this invention.

Figure 8 is a cross-sectional view taken on line 8 8 of Figure 7.

Figure 9 is an elevational view of a modification of the apparatus shown in Figure 1 with certain identical parts omitted.

Figure 10 is a cross-sectional view taken on yline lli-I 0 of Figure 9.

fifi

This invention makes use of the fact that nylon threads can be given a permanent set by the application of heat. In carrying out the invention selected stitches of a fabric are enlarged, thus stretching 4portions of the threads without damage thereto, and then subjected to heat to set the thread portions permanently in their stretched condition. The stitches or points 1in the fabric which are so enlarged form small holes in the fabric, and the location of such points of enlargement may be chosen so that the small holes are arranged to form any open work design desired, such as letters, numerals, pictorial representations, or any other type of design. The selected stitches are stretched and the small holes formed by the insertion of a pointed element through the fabric between the threads at the desired locations or points of the fabric. Heat is applied while the elements thus pierce the fabric, and then the elements are withdrawn, leaving the small holes permanentlyV set in the fabric to form the desired design.

The heat applied to the fabric to set the open work design therein must be confined within certain temperature limits. Nylon melts at about 488 F., while its tensile strength is affected at temperatures over 356 F. Therefore, the temperature must be kept below 488 F. and preferably is kept below 356 F. On the other hand, to impart a set to nylon threads, the heat applied should be over about 250 F. Therefore, temperatures in the range from about 250 F. to about 360 F. may be employed safely. The period of time necessary to set nylon threads by the application of heat varies somewhat with the applied temperature. It has been found in practice that a period of from about one-half to about ve minutes usually is suiiicient for temperatures between 250 F. and 360 F.

Having thus described the method of the in vention, one form of apparatus for practicing the invention is shownsin Figures l to 4. A fabric supporting plate 20 has a plurality of holes 2l extending normally therethrough, and preferably arranged in a series of evenly spaced rows A with the hole-spacing in each row being the same, i. e., the holes are evenly spaced in two dimensions. The actual arrangement of the holes, such as the number of holes 2i in each row and their spacing, depends on the type'and number of different kinds of designs for which the apparatus is to be used. A pointed member or pin 22 is supported in each of the holes 2E with the pointed end 23 thereof normally positioned within the holes and below the fabric supporting surface 3 of the plate 20. The pointed ends 23 are adapted to be projected out of the holes 2l and above the fabric supporting surface to pierce a fabric 24 secured in proper position on the plate in order to form small holes 25 therein, asbest shown in Figure 6. Any desired pattern or design in the fabric thus may be formed (within the limits cf the apparatus) by selectively projecting the pins 22. For example, as best shown in Figure y those pins 22 have been projectedwhich will'form the numeral 5I to produce the resultant fabric design shown in Figure 6.

The cross-sectional area of the pins221land the character of their pointed ends 23, i. e., whether extremely sharp or relatively blunt, depends upon the size of the threads and the number of courses, or threads, per inch in the fabric to be pierced,

but the cross-sectional area must be such that' the pin may be inserted through the thread Yloop of a stitch without causing breakage of a thread. Thefextreme-tip of the point of each pin22 pref-- erably is somewhat rounded so that thepins willV penetra-te between the threads of the fabric insteadofpenetrating between the fibers ofl a thread or yarn with consequent` damage thereto. The pins may have any desired shape in transverse section, but preferably are circular, as shown, for a purpose described later.

Secured below theV fabric supporting plate 2Q is a base plate 25-.having a plurality of holes 22' therethroughcorresponding in number and arrangement tothe holes 2| in the fabric supporting plate. rIhe pins 22 extend through the holes 21 in the basev plate withthelower ends 25 depending therebelow. A pattern member 29` is mounted beneaththe base plate for upward movement against the depending lower ends 28 of the pins.l Asshown in the drawings, the pattern member may be detachably hinged, as at Sii, to vone edge of the baseplate 25 and any suitable-mechanism, not shown, may beemployedfor moving the pattern member upwardly against the pins. The pattern' member 29 has a pluralityv of holes 3l therein of larger diameter than the lower ends of the pins 22. The holes 3| correspond to those pins which are not to be raised during the formation of a selected design. As shown best in Figures 1 and 4, the holes 31 correspond to those pins which are not raised during the formation of the numeral 5L Accordingly, it will be seen that upward movement of the pattern member 29 against the depending lower ends 28 of the pins projects the points 23 of selected pins from the holes 2| in the fabric supporting: plate Vto pierce the fabric 24. It is obvious that the pattern member may have projections thereon to contact those Ypins desired to be raised, instead of having openings therein to receive those pirs which are notto be raised. It also will be seen that the fabric design formed by the pointed ends 23 may be changed by the substitution of a different pattern member. If desired, the pattern member and the base plate may be provided with intertting guide lugs 32 and openings 33, as shown, to insure proper registration of the holes 3i in the pattern member with the depending ends 2S of the pins.

It has been found that the pointed ends 23 of the pins will penetrate between the threads of fabric more easily and with less chance of darnage to the threads when the pins are rotated during their axial piercing movement. If such rotation is effected, that portion of the pins which pierces the fabric must, of course, be cylindrical in transverse section in order to avoid severe damage to the fabric. One method of rotating the pins is by means of gears. As shown best in Figures 1 and 2, the pins 22 in each row are rotatively connected together by gears 34 mounted on an intermediate portion of each pin. The gears 3Q have an axial length sufficient to retain their mesh with adjacent gears when axially displaced relative thereto upon projection of selected pins, asbest shown in Figure 1. Thus, all the pins in each row will be rotated by rotation of any one pin in the row. Accordingly, one pin in each rowA may be rotated by any suitable gear trainfjournaled between the plates 20 and 26, such as .the idle-gears 35, two of which are driven by the driving gear 35 and one of which is in driven engagement-.with a gear 34 on a pin in an adjacent row. Thedriving gear 36 may be driven by a belt 31, which is connected to any suitable source of power, such as an electric motor, not shown, or by any other suitable conventional means. It will be noted that the gears 34 serve asistops to retain the pins 22y in proper position between the plates 20 and 26.

Because of the friction between the meshing gears 3d on the pins 22 during. relative axial displacement, it is desirable to provide springs 3S, mounted on thepins between the gears 3 andthe fabric supporting plate 2%), to retract or withdraw the pins from the fabric when the pattern member 29 is lowered into inoperative position.

If desired, suitable connections (not shown) may be provided between the pattern member and the source of power for driving the belt it?l so that the source of power will be started by the initial movement of the pattern member into operative position and stopped when the `member reaches full operativel position' and the piercing of the fabric has-been accomplished.

In Figures 9 and 10 is shown another form of apparatus for causing rotation of the-pinsY 22 during their axial movement to pierce the fabric 24. Mounted between the twoplates-20 and 26v is an intermediate plate 39-to..which the pins 22` are helical-ly splined, as by alhelical thread or spline le on each of the` pins which cooperates with a notch d! in the periphery of a correspondl ing hole in the intermediatev plate. Such a helical spline. could, of course, be accomplished as well by providingy a helical groove, not shown, on each pin into which a tooth projectsfrom: the periphery of the. corresponding hole inthe plate 39. It.will be seen that with either spline construction, axial movement of the pins, to pierce the fabric, will cause simultaneous rotation thereof. Hence, movement of a pattern` member (not shown in Figure 9) intoV operative position, is suicient to both rotate and project the pins into a position, such asV that shown. In this construction, the pins are provided with collars 42 which serve as stops inV place of the gears 3. withdrawing springs. 38 are also. provided.

Cooperating with the. fabric supporting plate is a fabric clamping plate A3 which has a plurality of holes 44 therein corresponding in size-, number, and arrangement to the holes 2l inthe plate 2. TheV holes treceivethe ends 23 of the pins when the latterV are projected to pierce fabric clamped between the two plates 20 and 43. The clamping plated3 may bey hinged to one edge of the supporting plate, 20, as at 45, and preferably means, such las lugs 46 and pivoted thumb screws 41, are provided for locking the plates together in fabricclamping position.A

That area of the fabric clamped between the two plates which is pierced by therme. maybe heated in various ways to set the design therein'. As shown in Figures 1 and 3, the clamping plate 43 may be provided with an electric heating coil 48 mounted in a compartment 49 which overlies the ends 23 of the pins. The electric circuit for the heating coil 48 preferably includes an adjustable thermostat 50, of a suitable type, so that the temperature to which the plate 43, and consequently fabric, is heated readily may be controlled.

There is shown in Figure another method of heating the fabric while it is clamped between the plates 20 and 43. A steam jacket 5| surrounds the apparatus on three sides to heat the fabric supporting plate. Steam underpressure may be supplied to the jacket, through inlet and outlet connections 52 and 53, from any suitable source of supply and the temperature controlled in any conventional manner.

The operation of the apparatus shown in Figures 1 to 5 and 9 is as follows. which a design is to be applied is placed smoothly over the supporting plate 20 and the clamping plate 43 lowered and locked to clamp the fabric therebetween. If gears, instead of a helical spline, are provided to rotate the pins 22, the source of power to rotate the gears is started and the pattern member 29 raised to operative position, thus piercing the fabric with the selected pins. Rotation of the pins then may be stopped and the electric circuit to the heating coil 48 closed, or steam let into the steam jacket 5| if the latter type of heating means is provided. The fabric is left in pierced position betweenrthe plates for a period of from about onehalf to about ve minutes while heated to a temperature of from about 250 F. to about 360 F. The pattern member then is lowered to permit the pins to withdraw, the clamping plate unlocked and raised, and the fabric removed. If desired, heat may be supplied to the apparatus constantly, provided suitable apparatus, such as the thermostat 50, is incorporated in the heat supply to maintain the temperature at the desired degree.

Nylon stockings must be preboarded before being dyed in order to give shape thereto. If this operation is not performed and if a nylon stocking is dyed loose in a hot dye bath, like silk or other fiber stockings, and dried on a form, the result is a wrinkled misshapen stocking. Hence, nylon stockings are preboarded, i. e. placed on a form and subjected to live steam at about 282 F. for about ve minutes before being dyed. The stockings then retain a permanent set. Other setting agents are described in U. S. Patent No. 2,157,119. The process of this invention may be performed on nylon stockings before or after the preboarding treatment. It also has been dis- The fabric to covered that the process can be performed as a part of the preboarding treatment.

Suitable apparatus for forming a design in a nylon stocking simultaneously with the preboarding treatment is shown in Figures 7 and 8. A relatively thin plate 54 is secured to an attaching member 55 which has curved ends 56 for adjustable attachment to a preboarding form 51. Projecting from the plate 54 are a plurality of pointed pins 58 arranged to form any selected design, such as the numeral 5l as shown. The pins 58 are long enough to project through the fabric of a stocking between the threads to enlarge selected stitches and form small holes in the fabric. In use, the apparatus is attached to a preboarding form and the stocking drawn thereon. That portion of the fabric overlying the pins 58 is pressed down to force the pinsthrough the fabric. The stocking is then subjected to the heat and moisture of the preboarding process and afterwards stripped from the form 51. The heat and moisture will have s et the design in the stocking.

Numerous changes in the apparatus shown and described and modifications of the methods disclosed herein will be apparent to one skilled in the art. Hence, the invention embraces all variations thereof that come within the spirit and scope of the following claims.

I claim:

1. The method of forming a design in a stocking knitted from synthetic polyamide fibers the steps comprising: placing the stocking on a preboarding form; stretching portions of the threads to enlarge the normal distance therebetween at selected points of the stocking by inserting a pointed element through the stocking between the threads at said points; and subjecting the stocking to preboarding treatment.

2. The method of forming a design in a stocking knitted from synthetic polyamide fibers, the steps comprising: placing the stocking on a preboarding form; stretching portions of the threads of the stocking on the form to enlarge the normal distance therebetween at selected points of the stocking fabric by inserting a pointed element through the stocking between the threads at said points; and subjecting the stocking on the form to preboarding treatment while said thread portions are in their stretched condition.

FRANK G. WEISBECKER.

REFERENCES CITED UNITED STATES PATENTS Name Date Seemuller July 15, 1947 Number 

1. THE METHOD OF FORMING A DESIGN IN A STOCKING KNITTED FROM SYNTHETIC POLYAMIDE FIBERS THE STEPS COMPRISING: PLACING THE STOCKING ON A PREBOARDING FORM; STRETCHING PORTIONS OF OF THE THREADS TO ENLARGE THE NORMAL DISTANCE THEREBETWEEN AT SELECTED POINTS OF THE STOCKING BY INSERTING A POINTED ELEMENT THROUGH THE STOCKING BETWEEN THE THREADS AT SAID POINTS; AND SUBJECTING THE STOCKING TO PREBOARDING TREATMENT. 